onedumslack's build

[onedumslack]

I purchased this car in March of 2014 and have been slowly retrofitting, modding, and upgrading.
Found it on a craigslist ad 400 miles away after 3 months of searching.
It was all stock with an irreparable hood and an apr stage 1 tune.
Drove the next day to Los Angeles to pick it up and bring it home to Phoenix.

Here's the car as it sits now.








Turbo:
K04 hybrid
PTP K04 turbo blanket

Intake:
ECS Luft Technik CAI
Evolution Racewerks duel sport smic
Silicone turbo inlet hose
Intercooler silicone hose set
Snow performance stage 2 meth injection
Dual nozzle kit meth injection

Fueling:
Loba high pressure fuel pump
S3 injectors
155 bar prv hpfpupgrade.com
RS4 lpfp controller

Engine:
Fluidampr crank pulley
Okada coil packs

Exhaust:
Unitronic 3" HFC/Downpipe
Vibrant Performance 3" to 2x 2.5" Merge Collector
Vibrant Performance 2.5" Ultra-Quiet Resonators
Remus mufflers
Custom piping with vband clamps

Drivetrain and Mounts:
lightweight flywheel and stage 1 clutch combo
4:1 center diff upgrade
034 Motorsports street density transmission mount
RS4 B5 engine mounts
ECS rear differential mount
034 Motorsport rear differential carrier mount insert kit

Interior Retrofits/Upgrades:
Two tone B6 Recaros
Partial S4 black interior swap
S4 nappa leather armrest
S4 carbon fiber trim
BFI Swartz heavy weight shift knob
short throw shifter
RS4 ebrake
Flat bottom air leather steering wheel
VFIZ cluster gauge
RS4 pedal set
Interior LED's
Auto dim rear view mirror
Color DIS
Funk button for meth injection control

Exterior Retrofits/Upgrades:
3M Crystalline Series tint
OEM bi-xenons + sti lenses + clear caps + joey mod + OEM turn signal chrome bulbs
Auto dimming power folding side mirrors with euro glass
Auto windshield wipers with rain/light sensor
Cupra r front lip
Relak side skirts
Votex rear diffuser
DTM replica carbon fiber rear trunk spoiler
Titanium sline grill
Black mirror caps
Black vinyl window trim

Wheels, Suspension, Braking:
Forgestar F14 17" lightweight wheels
World Motorsports titanium lug bolts
Q5 320mm brembo front calipers
S4 rear calipers
lightweight front and rear rotors
Goodridge G-Stop Brakeline Kit
RS4 rear sway bar

Other:
Optima Yellow Top Battery

Stereo:
Xtrons head unit
Backup camera
Infinity Kappa 60.11CS 6-3/4" component speaker system
Pioneer GM-D8604 Class FD 4-Channel Bridgeable Amplifier
Stock Bose 8" subwoofer
JBL GX-A3001 Mono Subwoofer Amplifier
12WXv2-4 - JL Audio 12" 200W RMS 500W Max Single 4-Ohm WXv2 Subwoofer
JX250/1 - JL Audio Monoblock 250W RMS 500W Class A/B Amplifier
Rockford Fosgate RFK4D 4 AWG Dual Amplifier Install Kit
Rockford Fosgate RFK8 8 AWG Power Only Amplifier Install Kit
AudioQuest - Golden Gate audio interconnects RCA-TO-RCA
AudioQuest G-2 bulk speaker cable
SDS CLD Tiles
1/2 Lb Mass Loaded Vinyl
Acoustic foam

#################################

Yet to install:
IE aluminum valve cover
340 lph lpfp

Engine Build:
APR Mahle 83mm 9.8:1 forged pistons
Pauter rods rifle drilled with rod groove thrusts
Mahle race main bearings
Mahle VP2 rod bearings
IE timing belt gear kit
ARP head studs and bolts kit
ARP main stud kit
ARP crank damper bolt
ARP cam tower bolt kit

#################################

Yet to purchase:
Borg Warner 6758 EFR twin scroll turbo

[onedumslack]

I purchased a spare motor with 62k on it to build.
Just got the block and head back from the machine shop after having the block bored out to 83mm and having custom pauter rods with apr mahle pistons installed.
The head was cleaned and had the bowls blended and short turns with upgraded ferrea valve springs.


Pics of the motor I picked up and dissembling:

[onedumslack]

Pics of the block and head after picking it up from the machine shop.

[aluthman]

Nice start to the build. My only bit of advice is to consider the 7163 over the 6758. From what I've seen, it outspools and makes more power through the entire rpm band due to the mixed flow turbine design. What is your plan for the manifold?

[onedumslack]

Nice start to the build. My only bit of advice is to consider the 7163 over the 6758. From what I've seen, it outspools and makes more power through the entire rpm band due to the mixed flow turbine design. What is your plan for the manifold?

Really, better spool? The only reason I was headed toward the 6758 is for the spool. I didn't realize the turbine design would have that big of an effect. I was basing it off some old dyno graphs from a similarly sized engine that had shown it spooling slightly quicker. I hadn't any plans yet for the manifold.

[aluthman]

To my knowledge, there are no commercially available twin scroll manifolds for our cars. Derrek and I had to make our own. I made a second one for matttl16.

[aluthman]

This isn't exactly what I was looking for, but it compares the two turbos. I'll keep looking for the thread I was reading the other day.
http://blog.perrinperformance.com/bo...test-and-tune/

[Operator]

Lots of info here too, and once you start clicking on the links it's like going down a rabbit hole of material. http://www.ft86club.com/forums/showthread.php?p=1997990

Depending on your budget the 7163 can also be about $600. Though you could see if the used one in the classifieds is still avail.


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[canadianA4B7]

Just picked up a 6758 and all new manifold and parts from pag parts. I'll be running the IRL hot side (.92 ar from the info if found) I'll have a spare 6758 super core out of this ordeal. It'll likely go up on eBay when it gets to me. If your interested shoot me a pm. I think a twin scroll 6758 shud spool quick. Not as quick as the 7163 but only a few 100 rpm behind it, should spool faster the the GTX 2863 I have run, and marginally faster the the GTX 2867 I'm running now.

If Aluthman wud be kind enough to vid the gauges in his car this could shine serious light as to how fast exactly the 7163 spools. (I may still switch to this setup but only if I can find interested buyers for the unused complete pag parts setup, and the Garrett complete kit. If interested shoot me a pm. I'll sell anything right now as the cars going into storage soon so it doesn't need turbo or manifold untill next spring.

[aluthman]

If Aluthman wud be kind enough to vid the gauges in his car this could shine serious light as to how fast exactly the 7163 spools. (I may still switch to this setup but only if I can find interested buyers for the unused complete pag parts setup, and the Garrett complete kit. If interested shoot me a pm. I'll sell anything right now as the cars going into storage soon so it doesn't need turbo or manifold untill next spring.

I posted a video in my thread trying to show how fast it spools on the base tune. My gopro was a bit shaky, but you can get an idea. The AWE boost gauge only goes to 25 psi for reference.

[derrek]

Been waiting for you to make a build thread. If you're running ferrea retainers check to make sure the rocker arms dont hit them. That's a problem I've see happen with the newer style rocker arms. Also what engine code is that block? First time I've seen the cast main caps.

[onedumslack]

Thanks guys, I'll keep reading more. I have a bit before I actually follow through with the turbo purchase. I wanted to get the new engine in and confirmed running before purchasing the turbo. And I'm slow. I had seen that perrin performance link before but I thought it had been shown to be inaccurate for spool of the 6758 due to something with the turbo hardware they used. I don't see that on the link now though. I do however agree that the 7163 appears quite appealing from the spool vs power potential and if I were choosing the 6758 in twin scroll, I had the impression it was basically a slightly quicker spool than a k04 but capable of flowing much more peak. But from its specs I might be looking to want to push it too hard. My friend here just purchased a Tig welder not to long ago so we figured we'd experiment doing the twin scroll manifold ourselves when the time comes.

Yeah Derrek, it took me so long to get to this point I didn't want to post a build until I actually had something started with the engine. It's a BWT engine code pulled from a 2008 CVT. Is cast main caps possibly bad? Thanks I'll check on the retainers.

[aluthman]

BPG and at least some of the BPY (probably the earlier ones) had the forged main caps. The only BWT I've opened also had cast main caps. VAG really cheaped out on the BWT engines.

[derrek]

Thanks guys, I'll keep reading more. I have a bit before I actually follow through with the turbo purchase. I wanted to get the new engine in and confirmed running before purchasing the turbo. And I'm slow. I had seen that perrin performance link before but I thought it had been shown to be inaccurate for spool of the 6758 due to something with the turbo hardware they used. I don't see that on the link now though. I do however agree that the 7163 appears quite appealing from the spool vs power potential and if I were choosing the 6758 in twin scroll, I had the impression it was basically a slightly quicker spool than a k04 but capable of flowing much more peak. But from its specs I might be looking to want to push it too hard. My friend here just purchased a Tig welder not to long ago so we figured we'd experiment doing the twin scroll manifold ourselves when the time comes.

Yeah Derrek, it took me so long to get to this point I didn't want to post a build until I actually had something started with the engine. It's a BWT engine code pulled from a 2008 CVT. Is cast main caps possibly bad? Thanks I'll check on the retainers.

If I were building for big power I'd be a little concerned but the 1.8t' all have the same cast main caps. If you were to swap them now you'd need to get the ie caps and have the machine shop take everything apart and machine the caps to fit. Not worth it IMO.

For turbos I can give you a ride in my car when it's back together in a few weeks. When it ran on 3 cylinders it was t spooling much later then my k04 and had way more top end of less then half the boost. I think you should really be looking at a 7163 sized turbo.


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[onedumslack]

If I were building for big power I'd be a little concerned but the 1.8t' all have the same cast main caps. If you were to swap them now you'd need to get the ie caps and have the machine shop take everything apart and machine the caps to fit. Not worth it IMO.

For turbos I can give you a ride in my car when it's back together in a few weeks. When it ran on 3 cylinders it was t spooling much later then my k04 and had way more top end of less then half the boost. I think you should really be looking at a 7163 sized turbo.


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I see. Yeah, when I saw main caps I also saw a minimum of another $1,800 for parts plus labor in my head. I'll go ahead and look up some 1.8t builds to check them out.

[derrek]

I see. Yeah, when I saw main caps I also saw a minimum of another $1,800 for parts plus labor in my head. I'll go ahead and look up some 1.8t builds to check them out.

Here's one of my forged main caps for reference.






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[jbain2]

Nice list. Swap out that crappy 2.0 oil filter housing while the motor is out. Did you just do valve springs or valves as well?

[derrek]

Nice list. Swap out that crappy 2.0 oil filter housing while the motor is out. Did you just do valve springs or valves as well?

What makes you say the 2.0 oil filter housing is crappy?

[jbain2]

What makes you say the 2.0 oil filter housing is crappy?

Just not a big fan. Personally I find it too finicky. Over torque the thing and the seal bunches or the housing cracks. Under torque and you are leaking oil. I prefer the conventional filter housing that VAG has used in the prior generations.


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[onedumslack]

Just not a big fan. Personally I find it too finicky. Over torque the thing and the seal bunches or the housing cracks. Under torque and you are leaking oil. I prefer the conventional filter housing that VAG has used in the prior generations.


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I didn't want to deal with the oil pressure issues. Some are good and some are not. I'd rather just leave it alone. Yeah, I only did the springs.

[onedumslack]

If I were building for big power I'd be a little concerned but the 1.8t' all have the same cast main caps. If you were to swap them now you'd need to get the ie caps and have the machine shop take everything apart and machine the caps to fit. Not worth it IMO.

For turbos I can give you a ride in my car when it's back together in a few weeks. When it ran on 3 cylinders it was t spooling much later then my k04 and had way more top end of less then half the boost. I think you should really be looking at a 7163 sized turbo.


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I forgot to tell you, thanks for the offer, I would really appreciate checking out your setup. Please let me know when you'd have time for that.

[onedumslack]

It's been awhile but I have made some progress. I got the engine fully assembled but I have not swapped it in yet. Instead, the price of the group buy on the K04-R was too good to pass up with the fact it comes with a manifold and fit's to my unitronic hfc unmodified so I went ahead and purchased the K04-R for now and wanted to run it before swapping the engine and then wanted to run it for a bit after swapping the engine to make sure the engine was good before I put more money into an efr setup. So this weekend I installed the K04-R and the base safe tune. So I started logging to send to JHM for the non base safe tune.

[EvolutionArmory]

Congrats on moving forward. The K04R is fun on the “safe” tune. Can’t wait to see what you do with a tune better suited to your actual car. I wish they would produce their OTS revised tune already. It’s been a minute now. You would think the popularity of the group buy would motivate them to get it out there 😀

[onedumslack]

Congrats on moving forward. The K04R is fun on the “safe” tune. Can’t wait to see what you do with a tune better suited to your actual car. I wish they would produce their OTS revised tune already. It’s been a minute now. You would think the popularity of the group buy would motivate them to get it out there 😀

Thanks, yeah, I'm hoping to be able to provide all the logs they request soon. I tried for the second set of logs last night but they requested block 026 and when I started vcds block 026 doesn't exist on mine. So I think it might be time I retired my China vcds cable and purchase a new rosstech cable.

[derrek]

Decided to go with the JHM k04 what happened with the EFR project? Also I'd love to grab some logs from the jhm k04 setup.

[onedumslack]

Decided to go with the JHM k04 what happened with the EFR project? Also I'd love to grab some logs from the jhm k04 setup.

The plan is still efr. I just grabbed this for now cause it offered the least amount of downtime for me since it's a direct swap with the k03 and for the price I figured I could resell it and not lose too much money on it. And I'm tired of driving around with all the other mods and no turbo. So I wanted to run this turbo for a bit once I swap the motor in. I'm baby stepping it. I'm all for some more logs once the proper tune gets put in. So far the logs of the safe tune show rail pressure is really limited, low maf values, and boost dropping after 5000k so it seems way tuned down for now.

[canadianA4B7]

Which efr you planning? Cuz my cars off the road this week. I could be convinced to sell the efr 6758

[onedumslack]

Which efr you planning? Cuz my cars off the road this week. I could be convinced to sell the efr 6758

I wanted the 6758 in twin scroll but I'm not quite ready to purchase that yet. Want to get my built motor installed first and make sure it's good. I'm guessing I won't be ready for a different turbo for another 6 months.

[onedumslack]

These are the logs that I took with this jhm K04-R safe tune to send to jhm. Would anyone that's more familiar with logging mind checking them out? From what I can tell it seems that boost is fine and that the turbo is performing to the requested values. However I had a concern on the timing pull. Not sure if this would be expected behavior for a safe tune or if there's a hardware issue I should be addressing. I don't throw any codes with a vcds scan. While I've been waiting for jhm to get back to me on these logs I also decided to see if spraying meth would help with the timing pull since I didn't plan to get tuned for meth but rather just help with temps and timing. But with meth I seem to have the same results.

https://drive.google.com/file/d/0B0Z...ew?usp=sharing
https://drive.google.com/file/d/0B0Z...ew?usp=sharing
https://drive.google.com/file/d/0B0Z...ew?usp=sharing

[onedumslack]

Here's the next set of logging after getting a revision of the tune.
https://drive.google.com/file/d/1Zy1...ew?usp=sharing
https://drive.google.com/file/d/1rWH...ew?usp=sharing

[onedumslack]

3 months later and jhm still doesn't respond back from these logs.

[arankaspar1]

How do you like the Witson head unit? I'm really interested in the Pioneer with Apple CarPlay but I could do with a more simple unit if it's quick and responsive.


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[onedumslack]

How do you like the Witson head unit? I'm really interested in the Pioneer with Apple CarPlay but I could do with a more simple unit if it's quick and responsive.


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Too many bugs. I wouldn't buy it again. It doesn't remember the last song it was playing after being off so it goes into a party mix mode instead and plays a random playlist. If they fixed that and also fixed and issue where it randomly decides it can't read my music files until it reboots then it would be good but they have no interest in real support. I'd look at the new xtrons instead if I was getting a new one.

[Denio24]

3 months later and jhm still doesn't respond back from these logs.

Wow I think it would be more time and cost effective to just learn tuning on your own!

[onedumslack]

Wow I think it would be more time and cost effective to just learn tuning on your own!

Yeah, they finally got back to me with the next revision about 3 weeks ago(so 5 months later) and asking for more logs. Now after this I have 0 motivation to go out risking taking logs. Wish I had just paid the small upgrade fee for making my apr stage 2+ into their k04 tune. It's still pulling 10 degrees of timing with the latest revision.

[Denio24]

Yeah, they finally got back to me with the next revision about 3 weeks ago and asking for more logs. Now after this I have 0 motivation to go out risking taking logs. Wish I had just paid the small upgrade fee for making my apr stage 2+ into their k04 tune. It's still pulling 10 degrees of timing with the latest revision.

^^ That is probably the reason why I will go with a local custom tune for my next turbo upgrade.

[onedumslack]

^^ That is probably the reason why I will go with a local custom tune for my next turbo upgrade.

I would have gone full custom if I had swapped the built engine in already. Only reason for this was cause of stock rods.